All this time drilling. Got all holes to 3/32, and somewhere less than half of them upsized to 1/8. Need to go slow and think about what is going on here. Some holes I want to stay at 3/32 until I get the angle stock on that backs them up. Also remember not to upsize holes at rib attach locations. That's pretty easy - I put masking tape on those clecoes so I don't pull them out. I made a spar cap spacer to set the width then double checked with the square. The spacer was just under 5 19/32. (just over 5 37/64) - I scaled that from the print, since I could not find where the dimension is given, but it worked out to give a nice snug check of 7 19/32 to the outsides of the spar. The photos I'm trying to show that the spar checker has to be flat against both extrusions to give a good check. Due to checking a peak-to-peak across the high spot on the extrusions, if it isn't flat (photos 2 and 3) the measurement will falsely look like the spar is too narrow, but it's not.
Distance check needs to be flat on both extrusions.
If it's lifted a little on one side, it looks like the spar isn't wide enough.
Due to angle on extrusion, measurement is only true if it's not lifted (as shown = bad).
